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US5733435A - Pressure driven solid electrolyte membrane gas separation method - Google Patents

Pressure driven solid electrolyte membrane gas separation method Download PDF

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US5733435A
US5733435A US08/811,671 US81167197A US5733435A US 5733435 A US5733435 A US 5733435A US 81167197 A US81167197 A US 81167197A US 5733435 A US5733435 A US 5733435A
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oxygen
membrane
feed
zone
stream
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Ravi Prasad
Christian Friedrich Gottzmann
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Praxair Technology Inc
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D71/00—Semi-permeable membranes for separation processes or apparatus characterised by the material; Manufacturing processes specially adapted therefor
    • B01D71/02—Inorganic material
    • B01D71/024—Oxides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/22—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by diffusion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/32—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by electrical effects other than those provided for in group B01D61/00
    • B01D53/326—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by electrical effects other than those provided for in group B01D61/00 in electrochemical cells
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2325/00—Details relating to properties of membranes
    • B01D2325/26—Electrical properties

Definitions

  • This invention relates to procedures for separating oxygen from a mixed gas feed stream and, more particularly, to a method for employing a solid electrolyte membrane for removing oxygen to purify the feed stream.
  • An entirely different type of membrane is made from inorganic oxides, typified by calcium or yttrium-stabilized zirconium and analogous oxides having a fluorite structure. At elevated temperatures, these materials contain mobile oxygen-ion vacancies. When an electric field is applied across such an oxide membrane, the membrane will transport oxygen and only oxygen and thus act as a membrane with an infinite selectivity for oxygen. Such membranes are attractive for use in air separation processes. More recently, materials have been reported that exhibit both ionic and electronic conductivity. A membrane exhibiting such a mixed conduction characteristic can, however, transport oxygen when subjected to a differential partial pressure of oxygen, without the need for an applied electric field.
  • Gur et al. describe transport properties of inorganic, nonporous membranes based on mixed-conducting perovskites. High transport rates are reported, indicating opportunity for chemically driven membrane applications for selective separation or purification of oxygen. See “A New Class Of Oxygen Selective Chemically Driven NonPorous Ceramic Substrates", Part I, A-Site Doped Perovskites, Journal of Membrane Science, 75:151-162 (1992). Teraoka et al., in Chemistry Letters, pages 1743-1746 (1985) indicate that the rate of oxygen permeation through perovskite-type oxides increases with an increase in strontium or cobalt content. Iwahara et al.
  • oxygen transport occurs due to a presence of oxygen vacancies in the oxide.
  • Oxygen ions annihilate oxygen-ion vacancies which are highly mobile in the oxide. Electrons must be supplied (and removed at the other side of an oxide membrane) to make the reaction proceed. For materials that exhibit only ionic conductivity, electrodes must be applied to opposed surfaces of the oxide membrane and the electronic current is carried by an external circuit.
  • Chen et al. in U.S. Pat. Nos. 5,035,726 and 5,035,727 describe the use of solid electrolyte membrane systems for the recovery of oxygen.
  • Chen et al. employ an electrically-driven ionic conductor to achieve gas separation.
  • Chen et al. also mention the possibility of using mixed conductor membranes operated by maintaining an oxygen pressure on the feed side.
  • Chen describes the use of an electrically driven gas separation system wherein oxygen is extracted from a feed stream emanating from a compressor of a gas turbine system.
  • Chen et al. further teach that oxygen exiting from the permeate side of an electrically-driven ionic membrane may either be removed as a pure oxygen stream or mixed with a suitable "sweep" gas such as nitrogen.
  • a still further object of the invention is to provide such a multiple stage system which can utilize different materials or types of solid electrolyte membranes in each stage.
  • Yet another object of the invention is to provide an improved oxygen separation system which can utilize a portion of retentate to enhance oxygen transport through a solid electrolyte membrane.
  • This invention comprises a process for removing oxygen from a feed stream to obtain an oxygen-depleted product stream by applying the feed stream to at least one separator including a feed zone and a permeate zone separated by a solid electrolyte mixed conduction oxide membrane, driving a first portion of entrained oxygen in the feed stream from the feed zone to the permeate zone via the membrane by applying at least one of a purge stream and negative pressure to the permeate zone to remove oxygen therefrom by establishing a lower partial pressure of oxygen in the permeate zone, and withdrawing oxygen-depleted retentate as a product stream after entrained oxygen has been removed from the feed zone.
  • the process further includes directing a feed stream output from the feed zone of the first separator to a second feed zone of a second separator, the second separator provided with a second permeate zone separated from the second feed zone by a second solid electrolyte ionic or mixed conduction oxide membrane.
  • FIG. 1 is a schematic showing of a prior art, single stage, pressure-driven oxygen separation process
  • FIG. 2 is a schematic showing of a prior art, single stage, electrically-driven oxygen separation process
  • FIG. 3 is a schematic showing of a novel single stage, pressure-driven oxygen separation process which employs both a vacuum pump and a purge stream to enable a more substantial oxygen gradient across a mixed conduction oxide membrane;
  • FIG. 4 is a schematic showing of a dual stage, pressure-driven oxygen separation process configured in accordance with the invention.
  • FIG. 5 is a plot of power and purge flow versus purge pressure, showing the effect of purge vacuum level on performance of the system of FIG. 4;
  • FIG. 6 is a schematic showing of a dual stage, combined, pressure-driven and electrically-driven oxygen separation process employing a first stage purge stream;
  • FIG. 7 is a schematic showing of a dual stage, combined, pressure-driven and electrically-driven oxygen separation process employing a first stage vacuum purge;
  • FIG. 8 is a plot of power versus purge pressure and interstage oxygen showing the effect of stage one purge vacuum level in the system of FIG. 7;
  • FIG. 9 is a schematic diagram of an alternative dual stage oxygen separation process utilizing a portion of retentate to enhance oxygen removal.
  • a prior art pressure-driven oxygen separation apparatus 8, FIG. 1, employs a solid electrolyte mixed conduction oxide membrane 10.
  • a feed chamber 12 receives a gas flow (via inlet conduit 14) that has been compressed by compressor 16.
  • a permeate chamber 18 receives oxygen passing through membrane 10 and outputs the oxygen via conduit 20.
  • the partial pressure P 1 of oxygen in feed chamber 12 must be maintained at a high level to overcome the partial pressure P 2 of the pure oxygen in permeate chamber 18.
  • high power levels are required to achieve a sufficient oxygen partial pressure in feed chamber 12--rendering the system inefficient for high volume oxygen separation.
  • a prior art system 21, FIG. 2, utilizes an electrically-driven ionic oxide membrane 22 which acts as a solid electrolyte when a voltage from power supply 28 is applied thereacross by cathode 24 and anode 26.
  • a feed gas input conduit 30 feeds a gas having entrained oxygen at a feed mole percent concentration Xf.
  • the feed gas passes into feed chamber 32 and out via conduit 34 containing a product oxygen mole percent concentration Xp.
  • the electric potential applied by power supply 28 across membrane 22 creates the driving force to transport oxygen ions through membrane 22 and into permeate chamber 36. Output from permeate chamber 36 is taken via conduit 38.
  • the power required to achieve oxygen separation from the feed gas is extremely high and effectively renders the system impractical for removal of high concentrations of oxygen from the feed gas.
  • a novel system 31, FIG. 3, is similar to that of FIG. 1, with like elements numbered identically.
  • a purge gas having a low oxygen concentration is applied via conduit 40 to permeate chamber 18 and the compressor 16 is optional, as shown in phantom.
  • a vacuum pump 42 connected to output conduit 44 which draws a combined purge gas and permeate gas flow via conduit 44 as a waste stream that is discharged through conduit 46.
  • a portion of the retentate stream 43 is utilized as the purge gas in one embodiment.
  • a pressure-driven two stage apparatus 41, FIG. 4, carries out oxygen separation from a feed stream with increased efficiency.
  • Each separation stage is identical to that shown in FIG. 3, but the negative pressure levels applied by optional vacuum pumps 42 and 42', FIG. 4, are adjusted in one embodiment to different levels due to different partial pressures P 1 and P 1 ' of oxygen in feed chambers 12 and 12', respectively.
  • the negative pressure levels are adjusted in another embodiment to accommodate different oxygen partial pressures in the purge gases provided through conduit 40 and 40'. Note that the numbering of the second separation stage is identical to that of the first stage except that all of the numbers therein have primes appended thereto.
  • Both of the separation stages of FIG. 4 employ a pressure-driven process for the removal of oxygen from a feed stream, the process being enhanced in one embodiment by vacuum pumping of the permeate side of mixed conduction oxide membranes 10 and 10'. Further, purge streams are applied to both stages to further aid in control of the oxygen partial pressure in permeate chambers 18 and 18'. Anode-side purging and vacuum pumping greatly reduce oxygen partial pressures and thus make it possible to achieve a low value for the product oxygen mole fraction with economically attainable low pressure values of the feed stream.
  • the best allocation of mechanical work between optional compressor 16 and vacuum pumps 42 and 42' depends upon the particular application.
  • the negative pressure level, also referred to as the vacuum level, and purge stream flow into permeate chamber 18' will likely differ from that in purge chamber 18 due to the differing partial pressures of oxygen in feed chambers 12' and 12, respectively.
  • the specific levels of purge flow and vacuum will, as aforesaid, depend largely upon the application and upon the oxygen permeation characteristics of the mixed conduction membrane material.
  • a cleaning ratio is used to determine the purge flow rate, and is defined as follows: ##EQU1##
  • This ratio should be within the range of from about 0.8 to about 5.0, preferably within the range of from about 1 to about 2.5. Cleaning ratios in excess of this range are undesirable because of economic factors and availability of the purge stream in such amounts. Cleaning ratios in amounts below this range are also undesirable because membrane area requirements increase and the ability to achieve the desired purity levels may diminish.
  • the N 2 purification can be achieved with a purge flow rate of 75 NCFH and a pressure P 2 in permeate chamber 18 of 0.95 psia.
  • the resultant additional power for operating vacuum pump 42 is 2.73 kW.
  • the two stage process shown in FIG. 4 requires only 0.71 kW at point 78, FIG. 5.
  • the same purge gas containing 10% oxygen is used for both stages with atmospheric pressure in permeate chamber 18 and a pressure of 0.95 psia in permeate chamber 18'.
  • the mid-stage oxygen mole fraction X m was taken to be the theoretical minimum value given by
  • the flows and vacuum pump powers of system 41, FIG. 4, have been computed using the first stage purge pressure, provided as the X-axis of FIG. 5, and first stage purge flow rate, curve 76, as variables while maintaining a constant second stage product oxygen concentration of 0.05%.
  • Curve 70, FIG. 5, indicates that the vacuum power for the first stage becomes smaller as the first stage purge pressure P 2 increases toward atmospheric.
  • the second stage vacuum power, curve 72, is a weaker function of P 2 and varies in the opposite direction because as first stage purge pressure P 2 increases, less oxygen is removed in the first stage and more must be removed in the second stage. It is a realization of this invention that increasing the first stage purge flow significantly reduces the amount of first stage vacuum pumping required to achieve the desired final product oxygen concentration.
  • the total vacuum power, curve 74, is found to be at a minimum, point 78, when the first stage is not vacuum pumped. As above indicated, the total power at point 78 is computed to be 0.7 kW, which is considerably lower than the 2.73 kW power computed for the single stage process of FIG. 3. Thus, when an adequate quantity of purge gas is available, there is considerable advantage to a pressure driven process comprising at least two stages.
  • Pressure driven processes are attractive for situations where large quantities of oxygen are to be permeated through a mixed conduction oxide membrane.
  • the pressure driven process can also be used for removal of trace oxygen from the feed stream. This requires the oxygen partial pressure on the permeate side to be reduced to a level below that in the product stream. In practice, this can be accomplished by compressing the feed stream to a very high pressure, applying a very low vacuum level to the permeate and/or using a purge gas stream with a sufficiently low oxygen concentration.
  • Applicants have thus determined that there are significant advantages to using combined pressure-driven and electrically-driven oxygen removal stages to produce an oxygen-free product from a feed stream containing moderate concentrations of oxygen typically less than 21% oxygen, preferably below 10% oxygen, and more preferably below 5% oxygen.
  • a combined pressure-driven and electrically-driven, two stage oxygen separation system 51, FIG. 6, is shown comprising separators 50 and 52.
  • Separator 50 is substantially identical to that shown in FIG. 3 but does not include a vacuum pump coupled to permeate chamber 54.
  • Electrically driven separator 52 is substantially identical to the structure shown in FIG. 2. However, electrically driven separator 52 receives its feed stream from the outlet of pressure-driven stage 50 wherein a substantial percentage of oxygen already has been removed from feed stream 56.
  • a substantially similar separator structure is shown in FIG. 7 except that pressure-driven first separator stage 60 includes a vacuum pump 62 connected to permeate chamber 64. Electrically-driven stage 66 is structurally identical to separation stage 52 shown in FIG. 6.
  • Power has been calculated for the process configurations shown in FIG. 6 and FIG. 7.
  • a feed stream of 10,000 NCFH of gas e.g. N 2
  • the purge stream has been considered to contain 10% oxygen.
  • the cleaning ratio is 1.5.
  • the product oxygen concentration has been assumed to be 1 ppm.
  • Vacuum pump 62 (FIG. 7) has been assumed to be a one or two stage pump with an efficiency of 60% per stage.
  • the applied voltage has been assumed to be 150% of the value determined by the Nernst equation, corresponding to an over-voltage of 50%.
  • Electrically driven separation stages 52 and 66 have been assumed to operate at 800° C.
  • the low pressure streams are assumed to exhaust to atmospheric pressure.
  • the combined pressure-driven and electrically-driven, two-stage system in FIG. 6 exhibits a total electrical power requirement of 3.8 kW.
  • the feed gas was N 2 containing 2% O 2 at 175 psig.
  • the feed stream is compressed, if necessary, and transferred at elevated temperature to pressure-driven separation stage 50.
  • Permeate chamber 54 has applied thereto a stream of 2,000 NCFH of gas containing 10% O 2 at slightly above atmospheric pressure.
  • Pressure-driven separation stage 50 is capable of removing 55% of the oxygen from the feed stream to create a mid-stage stream with an oxygen concentration of 0.8%.
  • the remainder of the oxygen is removed in electrically-driven second separation stage 52 which operates at 800° C.
  • the required electrical power is 3.8 kW.
  • No electrical power is needed for the first stage since the purge stream is at atmospheric pressure.
  • the work expended in the first stage is the portion of feed compression work needed to drive a quantity of oxygen through the membrane in that stage. Since the selectivity of the mixed-conduction membrane is effectively infinite, there is no loss of the inert gas or of its partial pressure in the first stage process.
  • Vacuum pump 62 reduces the pressure in permeate chamber 64 in first separation stage 60.
  • Vacuum pump power is plotted as curve 88, FIG. 8, as needed to achieve the values of first stage purge pressure P 2 in permeate chamber 64 that are provided on the X-axis.
  • Total power, curve 82 is the sum of first stage vacuum pump power, curve 88, and second stage electrical power, curve 84.
  • Inter-stage oxygen mole fraction X m is plotted as curve 86. The minimum total power is seen to occur when the purge pressure is lowest (2 psia). The electrical power and vacuum pump power are effectively equal and the total power consumed is 1.03 kW.
  • a multiple stage system according to the present invention is preferred to enable use of different types of SELIC membranes, different grades of purge gas, or different combinations of negative pressure and purge.
  • SELIC refers to solid electrolyte ionic or mixed conductors that can transport oxide ions.
  • ionic membranes can be placed in different arrangements with mixed conductor membranes, preferably having an ionic membrane downstream of a mixed conductor membrane. This arrangement optimizes the ability of the preceding mixed conductor membrane to remove large amounts of oxygen from an oxygen-rich feed stream by a pressure-driven process, and the ability of the successive ionic membrane to extract oxygen from a low-oxygen feed stream by an electrically-driven process.
  • Mixed conductors are not as suitable for extracting oxygen down to very low oxygen partial pressures, and ionic conductors consume tremendous amounts of power when subjected to high-oxygen feed streams.
  • SELIC membranes utilized for multiple stage system include membranes formed of different ionic or mixed conductor materials.
  • a first stage membrane includes a mixed conductor perovskite which exhibits high oxygen ion conductivity but is unstable at very low oxygen partial pressures.
  • a successive stage membrane includes yttria-stabilized zirconia "YSZ" (ZrO 2 with 8% by weight of Y 2 O 3 ), which exhibits a much lower oxygen ion conductivity but is stable at low oxygen partial pressures.
  • SELIC materials can be combined together in a single membrane, such as one of the multiphase mixtures disclosed in U.S. Pat. No. 5,306,411 (Mazanec et al.), to tailor that membrane for the requirements of a particular stage.
  • different mechanical configuration can be used, such as a cross-flow geometry in the first stage, or in an electrically-driven second stage, in which permeate is withdrawn at right-angles to feed and retentate flows.
  • Different grades of purge gas are used economically in different stages according to the present invention.
  • a less expensive low-grade (higher oxygen concentration) gas is applied to the first stage while more-expensive, higher-grade (low oxygen concentration) gas is used only in the last stage.
  • the oxygen concentration of a successive stage purge is preferably at least ten percent lower, and more preferably at least fifty percent lower, than that of the preceding stage purge.
  • air serves as the purge gas in the first stage together with a negative pressure applied to the permeate by a vacuum pump, or with a higher feed pressure.
  • different vacuum levels are applied per stage, with decreasing negative pressure in successive stages. Decreasing negative pressures reduce the amount and quality of purge gas required to practice the present invention.
  • the negative pressure applied to a successive stage is preferably at least ten percent lower, and most preferably at least fifty percent lower, than that of the preceding stage.
  • the permeate must be cooled to below 100° C., preferably below 50° C., before it reaches a vacuum pump. It is desirable to recover the heat using a heat exchanger to warm the feed stream prior to contacting the first SELIC membrane.
  • the type and amount of purge used in a process according to the present invention depends on optimizing performance based on oxygen partial pressures and total pressures on both sides of the SELIC membranes.
  • Preferred flow rates range from zero (if sufficient negative pressure is applied to a closed-end permeate zone) to the same order of magnitude as the feed flow, more preferably from 5% to 30% of the feed flow.
  • Feed stream pressures typically range from one atmosphere to several hundred psia.
  • Negative pressures at the permeate side range from 0.5 psia to 12 psia, preferably 3-7 psia.
  • a single-stage permeation process utilizes different amounts of product as a purge stream for a mixed-conducting, solid-oxide-electrolyte membrane, such as that shown in FIG. 3.
  • the vacuum pump has been eliminated and a portion of the product has been taken as the purge stream for refluxing the low-pressure side of the membrane.
  • a production rate of 100,000 NCFH of nitrogen product has been assumed.
  • the product pressure has been taken as 100 psig and the waste is assumed to discharge to the atmosphere at 15 psia.
  • the operating temperature of the membrane is 800° C. (1470° F.) where the ionic resistivity is 0.9 ⁇ -cm.
  • the membrane thickness has been assumed to be 1 mm.
  • System 91 is suitable for bulk production of a low-oxygen-concentration retentate product 92, such as nitrogen product, from a feed stream 94 such as air.
  • a low-oxygen-concentration retentate product 92 such as nitrogen product
  • feed stream 94 such as air.
  • Different purge configurations including permeate and/or product purge are utilized as described below.
  • Feed stream 94 is compressed by compressor 96 and enters a heat exchanger 98 where the temperature of feed stream 94 is elevated by heat exchange with product stream 92, oxygen byproduct stream 100 and waste stream 102.
  • a trim heater 104 further elevates the feed stream temperature as desired.
  • the heated feed stream is applied to first separator 106, and a first portion of entrained oxygen is driven from the feed zone to the permeate zone via a first SELIC membrane, preferably a mixed conducting membrane.
  • the oxygen partial pressure P 2 in the permeate zone optionally is lowered by vacuum pump 108 in the construction illustrated with solid lines. Pure oxygen is thereby obtained as byproduct stream 100.
  • Feed stream output 110 is directed to a second feed zone of a second separator 112, and a second portion of oxygen, which is entrained in the feed stream output 110 from the first feed zone, is driven into a second permeate zone through a second SELIC membrane. Oxygen-depleted nitrogen is obtained as product stream 92.
  • the second permeate zone is purged with an external stream 114 having a low oxygen concentration, such as a nitrogen- or argon-rich stream from an air separation plant, if available.
  • a fraction or portion of product stream 92 is divertable through valve 116 to purge the second permeate zone.
  • the ratio of purge flow to product flow ranges from 0.05 to 5.
  • At least three other countercurrent arrangements for purging the first permeate zone are illustrated in phantom.
  • a fraction of first feed stream output 110 is divertable to the first permeate zone through conduit 120.
  • some or all of second permeate output 102 is delivered through conduit 122 to purge the first permeate zone.
  • a portion of product 92 and/or external stream 114 are delivered through conduit 124.
  • One or more combinations of these different purge stream arrangements are achievable through appropriate valve and conduit configurations, and are desirable when byproduct stream 100 is not required to be pure oxygen.
  • Progressively lower permeate pressures can be created by vacuum pumping to progressively lower pressures and/or by purging with gas streams containing progressively lower oxygen concentrations as described above.
  • the pressure-driven stage removes the bulk of the oxygen whereas the electrically-driven stage removes the last traces of oxygen to produce a high purity oxygen-free product.
  • the material compositions for the mixed conduction oxide membrane may be prepared from a variety of materials including those listed in Table 2 below.
  • ⁇ is the deviation from oxygen stoichiometry.
  • the x and y values may vary depending on the material composition.
  • Mixed electronic/ionic conductors of item 9 in Table 2 are dual phase mixed conductors that are comprised of physical mixtures of an ionically-conducting phase and an electronically-conducting phase.
  • Electrically driven SELIC membranes based on ionic conductors may be selected from the following materials in Table

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US5888272A (en) * 1997-06-05 1999-03-30 Praxair Technology, Inc. Process for enriched combustion using solid electrolyte ionic conductor systems
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US6139810A (en) * 1998-06-03 2000-10-31 Praxair Technology, Inc. Tube and shell reactor with oxygen selective ion transport ceramic reaction tubes
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US6319305B1 (en) * 1998-10-29 2001-11-20 Normalair-Garret (Holdings) Limited Gas generating system
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US20030039601A1 (en) * 2001-08-10 2003-02-27 Halvorson Thomas Gilbert Oxygen ion transport membrane apparatus and process for use in syngas production
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US6638575B1 (en) 2000-07-24 2003-10-28 Praxair Technology, Inc. Plasma sprayed oxygen transport membrane coatings
US6641643B2 (en) * 2000-10-10 2003-11-04 Generon Igs Inc. Ceramic deoxygenation hybrid systems for the production of oxygen and nitrogen gases
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US6767663B2 (en) 1999-08-12 2004-07-27 Inventqjaya Sdn. Bhd. Oxygen separation through hydroxide-conductive membrane
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BR9601078A (pt) 1998-01-06
JPH08309142A (ja) 1996-11-26
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